Fibers for non-woven fabrics having blends of polymers with high and low melt flow rates

ABSTRACT

A spunbond non-woven fabric includes a plurality of fibers. The fibers are formed from a polymer blend that includes at least one first polymer and at least one second polymer. A melt flow rate of the at least one first polymer is greater than a melt flow rate of the at least one second polymer, and the melt flow rate of the at least one second polymer is about 9 g/10 min to less than 18 g/10 min. The blend may include a percentage by weight of the second polymer that is greater than a percentage by weight of the first polymer.

REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/730,249, filed on Sep. 12, 2018 and entitled HOLLOW FIBERS ANDNON-WOVENS WITH BLENDS OF POLYMERS HAVING HIGH AND LOW MELT FLOW RATES,and also claims the benefit of U.S. Provisional Application No.62/814,355, filed on Mar. 6, 2019 and entitled FIBERS AND NON-WOVENSWITH BLENDS OF POLYMERS HAVING HIGH AND LOW MELT FLOW RATES, both ofwhich are hereby incorporated by reference in their entireties.

FIELD OF THE INVENTION

This application relates to non-woven fabrics and, more particularly, tonon-woven fabrics intended for use in applications, such as surgical,hygiene, and infection-prevention products, where good physical andmechanical properties are required.

BACKGROUND

Fibrous materials are used in a number of products related to surgicalprocedures, hygiene, and infection prevention. They may be used to formsurgical gowns, drapes, sterilization solutions, gloves, facemasks,protective apparel, disposable diapers, hygiene products, etc. In somecases, it may be desirable for the fibrous material to be lightweight,thin, and easy to use. While use of hollow fibers in such materials hasbeen proposed, existing non-woven materials based on hollow fibers havelimited mechanical and/or physical properties that make them unsuitablein the above-mentioned applications. For example, existing non-wovenmaterials formed using hollow fibers can soften and weaken understerilization temperatures. Such weakening of the fabric makes them moresusceptible to cuts, holes, and potential tears propagated during use,and thus makes the fibers unsuitable for inclusion in fabrics and othermaterials for use in many surgical, hygiene, and infection preventionapplications.

SUMMARY

The terms “invention,” “the invention,” “this invention” and “thepresent invention” used in this disclosure are intended to refer broadlyto all of the subject matter of the disclosure and the claims below.Statements containing these terms should be understood not to limit thesubject matter described herein or the meaning or scope of the claimsbelow. Covered embodiments of the invention are defined by the claimsbelow, not this summary. This summary is a high-level overview ofvarious embodiments of the invention and introduces some of the conceptsthat are further described in the Detailed Description section below.This summary is not intended to identify key or essential features ofthe claimed subject matter, nor is it intended to be used in isolationto determine the scope of the claimed subject matter. The subject mattershould be understood by reference to appropriate portions of the entirespecification, any or all drawings, and each claim.

According to certain embodiments of the present disclosure, a fiberincludes a fiber body having a length. The fiber body is formed from ablend of a first polymer and at least 10% by weight of a second polymer,a melt flow rate (MFR) of the first polymer being greater than a MFR ofthe second polymer. In various examples, a plurality of the fibers maybe formed as a spunbond layer on a REICOFIL® III line, on a REICOFIL® IVline, or on a REICOFIL® V line.

In some examples, the fiber may be a hollow fiber or a solid fiber.Optionally, when the fiber is a hollow fiber, the fiber body defines ahollow cavity. In some cases, the hollow cavity constitutes up to about25% of the volume of the fiber body.

In certain examples, a fabric formed with the hollow or solid fiber hasan improved mechanical property in at least one of a machine directionor a cross-machine direction compared to a fabric with a fibercomprising only the first polymer. In various cases, the improvedmechanical property includes at least one of a trap tear strength, astrip tensile strength, a puncture resistance, and a grab tensilestrength. In certain aspects, the at least one direction is the machinedirection. In various examples, a spunbond non-woven fabric includes thehollow fiber or solid fiber. A weight of the spunbond may be less than105 gsm.

According to certain embodiments of the present disclosure, a spunbondnon-woven fabric includes a plurality of fibers, and the fibers areformed from a polymer blend having at least one first polymer and atleast one second polymer. A MFR of the at least one first polymer isgreater than a MFR of the at least one second polymer, the MFR of the atleast one second polymer is less than 18 g/10 min, and the blendcomprises a percentage by weight of the second polymer that is greaterthan a percentage by weight of the first polymer

According to certain embodiments of the present disclosure, a spunbondnon-woven fabric includes a plurality of fibers, and the fibers areformed from a polymer blend including at least one first polymer and atleast one second polymer. A MFR of the at least one first polymer isfrom about 19 g/10 min to about 40 g/10 min, and a MFR of the at leastone second polymer is about 9 g/10 min to about 18 g/10 min. The blendmay include at least 10% by weight of the at least one second polymer,and an average diameter of each fiber is from about 13 microns to about22 microns.

According to certain embodiments of the present disclosure, a spunbondnon-woven fabric includes a plurality of hollow fibers, and the hollowfibers are formed from a polymer blend having at least one first polymerand at least one second polymer. A MFR of the at least one first polymeris greater than a MFR of the at least one second polymer, the MFR of theat least one second polymer is about 9 g/10 min to less than 18 g/10min, and the blend includes at least 10% by weight of the secondpolymer. The hollow fibers each include a fiber body that defines acavity within the fiber body, the cavity and the fiber body togetherdefine a total volume, and the fibers include a hollowness of at least5% by volume of the total volume.

Various implementations described in the present disclosure can includeadditional systems, methods, features, and advantages, which cannotnecessarily be expressly disclosed herein but will be apparent to one ofordinary skill in the art upon examination of the following detaileddescription and accompanying drawings. It is intended that all suchsystems, methods, features, and advantages be included within thepresent disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated toemphasize the general principles of the present disclosure.Corresponding features and components throughout the figures can bedesignated by matching reference characters for the sake of consistencyand clarity.

FIG. 1 is a sectional view of a fiber according to aspects of thecurrent disclosure.

FIG. 2 is a sectional view of another fiber according to aspects of thecurrent disclosure.

FIG. 3 is an example of a calendar bond pattern according to aspects ofthe current disclosure.

FIG. 4 is an example of another calendar bond pattern according toaspects of the current disclosure

FIG. 5 is a schematic of a process that may be used to form fibersaccording to aspects of the current disclosure.

FIG. 6 is a table of mechanical properties of fabrics formed from fibershaving various blends and weights according to aspects of the currentdisclosure.

FIG. 7 is a graph illustrating percent increase in tenacity of fabricsformed from fibers having various blends according to aspects of thecurrent disclosure.

FIG. 8 is a table of mechanical properties of fabrics formed from fibershaving various blends and weights according to aspects of the currentdisclosure.

FIG. 9 is a graph comparing mechanical properties of fabrics formed fromfibers having various blends and weights according to aspects of thecurrent disclosure.

FIG. 10 is a graph comparing mechanical properties of fabrics formedfrom fibers having various blends and weights according to aspects ofthe current disclosure.

FIG. 11 is a graph comparing mechanical properties of fabrics formedfrom fibers having various blends and weights according to aspects ofthe current disclosure.

FIG. 12 is a graph comparing mechanical properties of fabrics formedfrom fibers having various blends and weights according to aspects ofthe current disclosure.

FIG. 13 is a graph comparing mechanical properties of fabrics formedfrom fibers having various blends and weights according to aspects ofthe current disclosure.

FIG. 14 is a graph comparing mechanical properties of fabrics formedfrom fibers having various blends and weights according to aspects ofthe current disclosure.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedhere with specificity to meet statutory requirements, but thisdescription is not necessarily intended to limit the scope of theclaims. The claimed subject matter may be embodied in other ways, mayinclude different elements or steps, and may be used in conjunction withother existing or future technologies. This description should not beinterpreted as implying any particular order or arrangement among orbetween various steps or elements except when the order of individualsteps or arrangement of elements is explicitly described.

As used herein, mass flow rate (MFR) is measured according to ASTMD1238-13, entitled STANDARD TEST METHOD FOR MELT FLOW RATES OFTHERMOPLASTICS BY EXTRUSION PLASTOMER and published in 2013 (“ASTMD1238”) (incorporated herein by reference). MFR is expressed (SI units)in g/10 min, and is the mass of polymer, in grams, flowing in tenminutes through a capillary of a specific diameter (typically about 2mm) and length by a pressure applied via a range of standard weights ata specified temperature (e.g., 190° C. for polyethylene and 230° C. forpolypropylene). As used herein, a “high MFR” polymer is a polymer havinga MFR of greater than 18 g/10 min, and a “low MFR” polymer is a polymerhaving a MFR of from about 9 g/10 min to less than 18 g/10 min. High MFRpolymers have lower viscosities and have lower strength, while low MFRpolymers have higher viscosities and are typically much stronger thanhigh MFR polymers.

Fibers

Disclosed are fibers useful in non-woven fabrics to give the fabricsmechanical and/or physical properties that are improved over propertiesof known non-woven materials, making the fibers/nonwovens useful for anumber of different applications. In some examples, the fibers includeblends of low MFR polymers and high MFR polymers, and the blend includesat least 10% by weight of the low MFR polymers. In various examples, thefibers may also have an average diameter of less than about 30 microns.In certain examples, the fibers may be hollow.

FIG. 1 illustrates an example of a fiber 100 according to aspects of thepresent disclosure. In the example of FIG. 1, the fiber 100 is hollowand defines at least one cavity 106 that extends through the fiber alonga length of the fiber (e.g., along a direction of a fiber axis 101). Inother examples, the fiber 100 may be solid and need not define thecavity 106. As such, while a hollow fiber is illustrated, it will beappreciated that the following description is equally applicable tosolid fibers (fibers without a cavity 106). The terms “fiber” and“filament” are used interchangeably throughout the description and areintended to refer to the same product.

As illustrated in FIG. 1, a hollow fiber 100 includes a fiber body 102having an outer surface 104. The fiber body 102 extends longitudinallyalong the fiber axis 101, such that the fiber 100 has a length. Invarious examples, the fiber body 102 defines a hollow cavity 106 withinthe fiber body 102. The cross-sectional shape of the fiber body 102and/or the hollow cavity 106 should not be considered limiting on thecurrent disclosure, as in various examples, the fiber body 102 and/orhollow cavity 106 may have various cross-sectional shapes as desired.

The fiber body 102 may be formed from a blend of polymers. Inparticular, the fiber body 102 may be formed from a blend of at leastone high MFR polymer and at least one low MFR polymer. Examples of highMFR polymers include polypropylenes polymerized using a Ziegler-Nattacatalyst (Ziegler-Natta polypropylene). Examples of low MFR polymersinclude polypropylenes polymerized using a metallocene catalyst(metallocene polypropylene). Traditionally, melt-spun fibers have beenformed only from high MFR polymers because their lower viscositiesrender them easier to spin into filaments. Conversely, low MFR polymershave not been used in melt-spinning fibers, particularly hollow fibers,because their higher viscosities make it more difficult to spin thematerial into filaments. While high MFR polymers are more easily spun,the resulting solid fiber and/or hollow fiber often has mechanicaland/or physical properties that are weakened by high temperatures and/orother extreme conditions and/or due to the lower average molecularweight of the higher MFR polymer. For example, hollow fibers made fromhigh MFR polymers could soften and weaken during steam sterilization,rendering the fabrics into which they are incorporated more susceptibleto cuts, holes, and tears during use and thus making them unsuitable formany surgical, hygiene, and infection prevention applications. Moreover,hollow fibers are prone to collapse as the material is not strong enoughto retain the hollow structure of the fiber.

It has been discovered that a blend of at least one high MFR polymer andat least one low MFR polymer, where the blend includes at least 10% byweight of the at least one low MFR polymer may be formed into hollowfilaments or fibers and spun into fabrics or other products havingimproved mechanical and/or physical properties (e.g., stable duringsteam sterilization, puncture resistance, strength, etc.) compared tofabrics having fibers that are not blended. In various aspects, the lowMFR polymers may have a MFR of from about 9 g/10 min to about 18 g/10min. In one aspect, the blend (and thus the resulting fibers) includesfrom about 10% to about 90% by weight low MFR polymers, such as about10% by weight low MFR polymers, about 20% by weight low MFR polymers,about 30% by weight low MFR polymers, about 40% by weight low MFRpolymers, about 50% by weight low MFR polymers, about 60% by weight lowMFR polymers, about 70% by weight low MFR polymers, about 80% by weightlow MFR polymers, and/or about 90% by weight low MFR polymers. Variousother percentages of the low MFR polymers between 10% and about 90% mayalso be utilized.

In some examples, the polymer blend (and thus the resulting fibers) mayinclude from about 10% to about 90% by weight high MFR polymers, such asabout 20% by weight high MFR polymers, about 30% by weight high MFRpolymers, about 40% by weight high MFR polymers, about 50% by weighthigh MFR polymers, about 60% by weight high MFR polymers, about 70% byweight high MFR polymers, about 80% by weight high MFR polymers, and/orabout 90% by weight high MFR polymers. Various other percentages of thehigh MFR polymers between 10% and less than about 100% may also beutilized.

In addition to the low MFR polymers and the high MFR polymers, thepolymer blend may also include other components or additives. In suchexamples where additional components are added, the blend may includefrom about 0% to about 10% by weight of the additional components. Invarious aspects, the additional components may include plastomers,elastomers, pigments, fluorochemicals, antimicrobials, surfactants,anti-stats, and/or various other additives or combinations of additivesor other components. In one non-limiting example, the additive mayinclude titanium dioxide. Again, however, in some embodiments thepolymer blend is formed exclusively of low and high MFR polymers.

In some embodiments, the low MFR polymers have a MFR of from about 9g/10 min to less than 18 g/10 min. For example, in some cases, the lowMFR polymers have a MFR of about 9 g/10 min, about 10 g/10 min, about 11g/10 min, about 12 g/10 min, about 13 g/10 min, about 14 g/10 min, about15 g/10 min, about 16 g/10 min, about 17 g/10 min, and/or variouscombinations thereof. For example, the blend may include a single typeof low MFR polymer or two or more low MFR polymers that have a differentMFR, although it need not in other examples.

The high MFR polymers may have a MFR of greater than 18 g/10 min asdescribed previously, and in various cases, may be from about 25 g/10min to about 40 g/10 min. For example, in some cases, the high MFRpolymers may have a MFR of about 19 g/10 min, about 20 g/10 min, about21 g/10 min, about 22 g/10 min, about 23 g/10 min, about 24 g/10 min,about 25 g/10 min, about 26 g/10 min, about 27 g/10 min, about 28 g/10min, about 29 g/10 min, about 30 g/10 min, about 31 g/10 min, about 32g/10 min, about 33 g/10 min, about 34 g/10 min, about 35 g/10 min, about36 g/10 min, about 37 g/10 min, about 38 g/10 min, about 39 g/10 min,and/or about 40 g/10 min, various combinations thereof, or various othersuitable high MFR polymers. In some examples, the high MFR polymers havea MFR of about 35 g/10 min. Similar to the low MFR polymers, the blendmay include a single type of high MFR polymer or two or more high MFRpolymers that have a different MFR, although it need not in otherexamples.

In some examples, the polymer blend may include combinations of multiplelow MFR polymers and/or multiple high MFR polymers. For example, in somecases, the blend may include two or more low MFR polymers (e.g., one lowMFR polymer having a MFR of 9 g/10 min and the other low MFR polymerhaving a MFR of 11 g/10 min) and one high MFR polymer (e.g., the highMFR polymer has a MFR of 35 g/10 min). In other embodiments, the blendmay include one low MFR polymer and two or more high MFR polymers. Infurther embodiments, the blend may include one low MFR polymer and onehigh MFR polymer. In still other embodiments, two or more low MFRpolymers and two or more high MFR polymers may be used. Various othercombinations may be utilized.

In various examples, the polymers used as the low MFR polymers and/orthe high MFR polymers include a polyolefin such as, but not limited to,polypropylene (PP) or polyethylene (PE). In some examples, the low MFRpolymers and high MFR polymers may both be PP or PE, although they neednot be in other examples. For example, in other cases, the polymers maybe poly(lactic acid), poly(butylene succinate), metallocene polymers,ziegler-natta polymers, polyester, nylon, and/or various other polymersor combinations of polymers. In one example, the low MFR polymer is ametallocene propylene and the high MFR polymer is a ziegler-nattapolypropylene. In some aspects, mixing polymers of two or more MFRs mayhelp increase the percent hollowness of the resulting fiber bystabilizing the solid part of the hollow fiber and preventing orreducing the likelihood of it collapsing.

The hollow fibers described herein and formed with the blend of the lowMFR polymers and high MFR polymers have a fiber body that surrounds anddefines a cavity. The fiber body and the cavity together define a totalvolume, and the fiber has a hollowness that is defined herein as thepercentage of the total volume occupied by the cavity. In some examples,the hollow fibers may have a hollowness of up to about 40% (i.e., 40% ofthe volume of the fiber is hollow). In some examples, fibers formed withthe blend of the low MFR polymers and high MFR polymers may have ahollowness of from about 5% to about 40%, such as a hollowness of fromabout 10% to about 30%, such as a hollowness of from about 10% to about20%, such as a hollowness of from about 7% to about 15%, such as ahollowness of from about 7% to 10%. In certain examples, the hollowfibers may have a hollowness of from about 20% to about 25%.

In various examples, the fibers may be formed to have various suitableexternal diameters. In some examples, the fibers have an externaldiameter of less than about 30 microns. For example, in some cases, thefibers have an external diameter of from about 11 microns to about 27microns, such as about 11 microns, about 12 microns, about 13 microns,about 14 microns, about 15 microns, about 16 microns, about 17 microns,about 18 microns, about 19 microns, about 20 microns, about 21 microns,about 22 microns, about 23 microns, about 24 microns, about 25 microns,about 26 microns, and/or about 27 microns. In other examples, the fibersmay have an external diameter that is less than 15 microns and/orgreater than 30 microns. The smaller the diameter of the fibers, thefiner the fibers, and as such, smaller diameter or finer fibers may havean increased number of contact points with other fibers in a productcompared to larger diameter fibers, and the increased contact mayincrease the strength of the product. The smaller diameter fibers mayalso provide increased coverage compared to larger fibers. As discussedin detail below, in various aspects, the weight of the fibers and thediameter of the fibers may be controlled to control mechanical and/orphysical properties of products that utilize the fibers.

FIG. 2 illustrates an example of a fiber 200 that is substantiallysimilar to the fiber 100 except that the fiber 200 includes a sheathlayer 208 such that the fiber 200 is a bicomponent fiber. In variousexamples, the sheath layer 208 may be provided on at least a portion ofthe outer surface 104 of the fiber body 102. The sheath layer 208 may beformed from a polymer with a MFR that is higher than the MFR of the lowMFR polymers used to form the fiber body 102. In some examples, thepolymer forming the sheath layer 208 is also a high MFR polymer. Invarious aspects, the high MFR polymer of the sheath layer 208 may be thesame and/or may have the same MFR of the high MFR polymer used to formthe fiber body 102, although it need not be in other examples. In someexamples, the polymer forming the sheath layer 208 may be a polyolefin,although it need not be. In certain aspects, the sheath layer 208 mayinclude various additives to enhance one or more properties of anon-woven product formed with the fiber 200. As some non-limitingexamples, the additive may include fluorochemicals, antimicrobials,surfactants, pigments, anti-stats, and/or various other additives orcombinations of additives as desired.

Fibers according to the present disclosure provide a number ofadvantages over traditional fibers. Embodiments of the fibers formedfrom a blend of at least one low MFR polymer and at least one high MFRpolymer enjoy the benefits that each of the polymer types brings to theblend, while the drawbacks of each polymer is counteracted orneutralized by the other polymer in the blend. Thus, fibers may becustomized or tailored to produce desired results (e.g., materialsavings, increased strength, ease of manufacture, etc.).

For example, inclusion of low MFR polymers in the blend strengthens thefiber, rendering it less apt to collapse or break. In some cases, havingat least 10% by weight of the low MFR polymers strengthens the fibers.In various examples, the percentage of low MFR polymers is greater thanthe percentage of high MFR polymers.

This increase in structural integrity allows one to optionally make thefibers hollow (and enjoy the consequent material cost savings) withoutdetrimentally affecting the fiber's strength and other mechanical and/orphysical properties. The low MFR polymer is also better able towithstand the sterilization process without degradation. Thus, a fiberof the present disclosure may be formed to have the same or bettermechanical and/or physical properties as traditional fibers while usinguse less material (because they are hollow). Consequently, products intowhich they are incorporated may be more lightweight, may be thinner, andmay be stronger.

Alternatively, a fiber formed in accordance with embodiments disclosedherein could also use more material (i.e., the fiber is solid or has areduced percentage hollowness) to further improve its strength and otherproperties of the fiber. In such cases, fibers according to the presentdisclosure may have improved mechanical and/or physical properties(degradation resistance, strength, etc.) by virtue of the presence oflow MFR polymers while having the same solidness and/or hollowness astraditional fibers. Various other advantages may be provided with hollowfibers of the current disclosure, and the above listing should not beconsidered limiting.

Furthermore, inclusion of the high MFR polymer in the blend allows theblend—which includes low MFR polymers that are difficult to spin—to bespun into filaments more easily. Moreover, the blend forming the fibermay facilitate quenching and drawing of the fibers and enhance theeffects of those procedures (and thus the mechanical and/or physicalproperties of the fibers) compared to traditional fibers. Withoutwishing to be bound by theory, quenching and drawing may be facilitatedby both the exterior and the interior (through the hollow core) of thehollow fibers are exposed to treatment during the process. Improvedquenching and drawing may result in increased strength of the fibers andresistance to degradation, collapsing, defects, etc. compared totraditional hollow fibers. In various aspects, the low MFR polymer mayalso help the fiber maintain more hollowness without collapsing onitself because the low MFR polymer has a higher melt strength (and assuch, a greater percentage of the fiber has the higher melt strength),which may prevent the collapse of the hollowness during the drawingdown. Various other advantages may be realized with hollow fibersaccording to embodiments of the present disclosure, and those identifiedabove should not be considered limiting.

In various examples, one or more parameters of the fibers may becontrolled to produce products having improved mechanical and/orphysical properties. As one example, the blend of polymers is controlledto provide stronger hollow or solid fibers. In one non-limiting example,a strong blend of polymers includes 30% high MFR polymers and 70% lowMFR polymers. In another non-limiting example, a strong blend ofpolymers includes 20% high MFR polymers and 80% low MFR polymers.Various other blends of low MFR polymers and high MFR polymers may beutilized. As another example, the average diameter of the fibers iscontrolled (optionally in conjunction with a strong blend of polymers)to provide improved mechanical and/or physical properties. In onenon-limiting example, the average diameter of the fibers is controlledto be about 15 microns to about 20 microns, although various otheraverage diameters may be utilized. As an additional example, the percenthollowness of the fibers is controlled. In some cases, the fibers may besolid, while in other examples, the fibers may up to 40% hollow.

Fabrics

Also disclosed herein are fabrics formed from the fibers describedherein. The fibers described herein may be used to form a variety ofdifferent fabrics, including, but not limited to, spunbond non-wovenmaterials or fabrics. In general, a spunbond (also called spunlaid)non-woven includes a web of stretched fibers of a thermoplastic resin.Generally, the spunbond is produced by depositing extruded, spun fibersas a web onto a collecting belt (usually in a random manner) followed bybonding the fibers. In some examples, the fibers may form a spunbondfabric that is a single layer; however, in other examples, the fibersmay form a fabric that includes a plurality of spunbond layers. Further,the single or plurality of spunbond layers maybe combined with anothertype of layer such as a meltblown layer.

In certain aspects, spunbond fabrics described herein may beincorporated into products including, but not limited to surgical gowns,sterilization wraps, respirators, absorbent pads, wound care products,chemical protection apparel, filtration media, hospital towels, hospitalapparel, drapes, gloves, facemasks, sanitary napkins, diapers, SMSwraps, surgical products (SMS, spunbond, etc.), hygiene products (SMS,spunbond, etc.), and other types of protective and/or hygienic products.In other aspects, the fibers disclosed herein may be used to formvarious other suitable non-woven products. It will be appreciated thatdifferent polymer blends may be used to form the fibers depending on thedesired end-use application (e.g., a personal care application couldinclude one blend, a health care application could include anotherblend, an industrial application could use a further blend, etc.). Instill other embodiments, the fibers may be provided in filament form orin staple form that is spun into yarns. These yarns may subsequently beused to form any type of fabric or substrate, including, but not limitedto, knitted, woven, and non-woven fabrics and substrates. In some cases,the fibers could be used in carded thermally bonded non-wovens,hydroentangled non-woven materials (e.g., where cellulose or otherfibers are combined with layers of the fibers), bicomponent materials(e.g., where bicomponent materials can be used with the fibers), and/orvarious other applications.

In some examples, fabrics formed with the blended fibers may have a highweight or a low weight. As used herein, a “high weight” refers to lessthan about 105 gsm, such as from greater than about 30 gsm to about 105gsm, and low weight such as from about 6 gsm to about 30 gsm. In variousexamples, the weight of the fabric used may be controlled depending onthe desired product that incorporates the fibers. As some non-limitingexamples, the fabric may be a spunbond (S)—meltblown (M)—spunbond (S)wrap (i.e., a SMS wrap) (which includes a meltblown layer betweenspunbond layers), and may have a weight of from about 25 gsm to about105 gsm. In other examples, the fabric may be a surgical gown having aweight of from about 17 gsm to about 105 gsm, and/or a hygiene producthaving a weight of from about 6 gsm to about 15 gsm. It will beappreciated that the above ranges should not be considered limiting onthe particular products and are provided only as examples. While a SMSfabric is described, it will be appreciated that other patterns oflayers of spunbond and meltblown (or other layers) may be utilized. Forexample, a fabric may have SM layers, SMMS layers, S layers, SS, layers,SMMMS layers, SSMMS layers, etc. as desired.

In some examples, the fibers described herein form a spunbond non-wovenfabric. The spunbond non-woven fabric may have a calendar bond patternwith a bond area of from about 12% to about 35%, such as about 30%,although various other bond areas may be utilized. The percent bond areaon the fabric is determined by the bond pattern of the calendar roll,and the fabric strength correlates with bond area. In one non-limitingexample, the bond area of the calendar bond pattern is about 30%. Thebond area of the calendar bond pattern may be controlled (optionally inconjunction with the fiber average diameter, hollowness, and/or blend)to provide improved mechanical and/or physical properties.

FIG. 3 illustrates a non-limiting example of a calendar bond patternaccording to aspects of the current disclosure having a bond area fromabout 15% to about 35%. FIG. 4 illustrates another non-limiting exampleof a calendar bond pattern according to aspects of the currentdisclosure. In some non-limiting examples, the bond pattern area of FIG.3 is increased compared to the bond pattern area of FIG. 4. In somecases, products that include the stronger fiber blend (hollow or solid),a decreased fiber average diameter, and the improved bond area mayimprove coverage to improve the mechanical and/or physical properties inthe products. As one example, the improved coverage may help protect aweaker meltblown layer in the middle in the case of the SMS wrap. In onenon-limiting examples, a product with improved mechanical and/orphysical properties includes (i) fibers having a strong blend ofpolymers having 30% high MFR polymers and 70% low MFR polymers or 20%high MFR polymers and 80% low MFR polymers and (ii) a fibers having adecreased fiber average diameter of about 15 microns to about 20microns. Optionally, the product includes (iii) solid fibers and/or (iv)a bond area of from about 15% to about 35%, such as about 30%.

Method of Production

FIG. 5 illustrates an example of a spunbond web-making system 300 thatmay be used to form spunbond non-woven fabrics with the blended fibersas disclosed herein via a spunbond web-making process. In variousaspects, a composition with the blend of low MFR polymers and high MFRpolymers is provided in a hopper 302. In various aspects, the polymersmay be blended prior to being supplied to the hopper 302, or the hopper302 may be equipped with a blending device. The hopper 302 supplies theblended polymers to a heated extruder 304, which melts and homogenizesthe polymers. In other examples, the blend could be extrusion compoundedor be formed or blended through various other suitable mechanisms ortechniques. From the extruder 304, the melted polymer blend is suppliedto a spinneret 306. The spinneret 306 may include one or more openingsthat the blend is passed through to form the fibers (usually as a fibercurtain). In various examples, the shape and/or configuration of theopenings of the spinneret 306 may determine the shape and/orconfiguration of the fiber and/or any cavity formed therein.

After passing through the spinneret 306, the fibers may be quenched withair from an air generator 308. The fibers may then be melt drawn using afiber draw device 310. The fibers may be drawn to form the fiber with adesired length. After drawing, the fibers may be deposited for furtherprocessing as desired, such as crimping, texturizing, cutting,incorporation into a non-woven web, etc.

In other examples, the hollow (or solid) fibers described herein and/orproducts incorporating the fibers described herein may be produced inaccordance with the REICOFIL® III method and system sold by ReifenhauserGmbh & Co. Maschinenfabrik. The REICOFIL® III system and method isextensively described in U.S. Pat. No. 5,814,349 (“the '349 patent”).The '349 patent is hereby incorporated by reference in its entirety. Asdescribed in the '349 patent, the REICOFIL® III method and system caninclude: a spinneret that produces strands; cooling means below thespinneret for cooling the strands from the spinneret to form filaments;a stretching system that receives the thermoplastic filaments foraerodynamic stretching; a web-depositing system below the stretchingsystem in which a web of the tangled and stretched filaments aredeposited; a continuously circulating sieve belt for forming a web fromthe tangled filaments; means for forming an air inlet gap; a first pairof pressing rollers; a second pair of pressing rollers; means forming asuction shaft for drawing the filaments against the belt; and/or meansfor functionally separating the stretching system from the webdepositing system. In some cases, the REICOFIL® III system is a one-beamline with production speeds of up to 300 meters per minute, although itneed not be in other examples. In other cases, the system may be asingle beam line, a double beam line, a multiple beam line, etc. asdesired. In some cases, the number of beam lines may depend on thedesired number of layers in the final product. The spinneret may be atwo segment spinneret (meaning that the spinneret forms a hollow cavityin each fiber having two sides), a three segment spinneret (meaning thatthe spinneret forms a hollow cavity in each fiber having three sides), afour segment spinneret (meaning that the spinneret forms a hollow cavityin each fiber having four sides), spinnerets having various othersuitable designs, or various other suitable spinnerets. In certainexamples, the smaller segment spinnerets (e.g., two segment spinnerets)may form fibers having smaller openings (i.e., reduced hollowness)compared to those formed by greater segment spinnerets (e.g., foursegment spinnerets).

In various other examples, the hollow (or solid) fibers described hereinand/or products incorporating the fibers described herein may beproduced in accordance with the REICOFIL® IV method and system sold byReifenhauser Gmbh & Co. Maschinenfabrik. The REICOFIL® IV system andmethod are extensively described in U.S. Pat. No. 6,918,750 (“the '750patent”). The '750 patent is hereby incorporated by reference in itsentirety. As described in the '750 patent, the REICOFIL® IV method andsystem can include: a spinneret that produces strands; cooling meansbelow the spinneret for cooling the strands from the spinneret to formfilaments; an intermediate channel; a stretching system that receivesthe thermoplastic filaments for aerodynamic stretching; a tiering ordistribution unit; a continuously circulating belt or screen for forminga web from the tangled filaments; at least one first pair of pressingrollers; means forming a suction shaft for drawing the filaments againstthe belt; and/or means for functionally separating the stretching systemfrom the tiering or distribution unit. In some cases, the REICOFIL® IVsystem is a one-beam line with production speeds of up to 600 m/min,although it need not be in other examples. In other cases, the systemmay be a single beam line, a double beam line, a multiple beam line,etc. as desired. In some cases, the number of beam lines may depend onthe desired number of layers in the final product. The spinneret may bea two segment spinneret, a four segment spinneret, or various othersuitable spinnerets.

In other examples, the fibers described herein and/or productsincorporating the fibers described herein may be produced in accordancewith the REICOFIL® V method and system sold by Reifenhauser Gmbh & Co.Maschinenfabrik. A difference between the REICOFIL® V system and otherREICOFIL® systems is that the REICOFIL® V system has a higher throughput(e.g., 150-270 kg per hour and meter width compared to 120-200 kg perhour and meter width for REICOFIL® IV), a higher production speed (up to1200 m/min), and improved uptime.

EXAMPLES

The mechanical properties of spunbond fabrics having solid fibers orhollow fibers consistent with embodiments described herein were testedaccording to accepted industry standard methods. Each sample fabricincluded fibers with a different blend of a high MFR PP polymer and alow MFR PP polymer. In each case, the spunbond fabrics were formed witha four segment spinneret unless described otherwise. The properties ofthe fabrics were measured at room temperature unless describedotherwise. As used herein, the meaning of “room temperature” can includea temperature of from about 15° C. to about 30° C., for example about15° C., about 16° C., about 17° C., about 18° C., about 19° C., about20° C., about 21° C., about 22° C., about 23° C., about 24° C., about25° C., about 26° C., about 27° C., about 28° C., about 29° C., or about30° C. Unless otherwise specified, the term diameter refers to the fiberdiameter measured in microns. For each example discussed below, thespunbond fabrics for the particular example were all spun with the samesettings and parameters.

Example 1

Sample spunbond fabrics were formed by a spunbonding process and using afour segment spinneret. The spunbond fabrics had fibers with differentblends of Polymer 1 and Polymer 2. Polymer 1 was a polypropylenehomopolymer having a MFR of 35 g/10 min. and a density of about 0.900g/cm³, available from Exxon Mobil® as PP3155. Polymer 2 was apolypropylene homopolymer having a MFR of 14 g/10 min. and a density ofabout 0.905 g/cm³, available from Total® as M3661. The sample fabricswere tested according to the standards described below.

In this example, each sample fabric was a single spunbond layer of thefibers. The samples had the compositions shown in Table 1 below.

TABLE 1 Compositions of Samples 1-8 Sample % Polymer 1 % Polymer 2 1 1000 2 80 20 3 70 30 4 60 40 5 40 60 6 30 70 7 20 80 8 0 100

Tests 1-4 were each repeated twenty-four (24) times for each Sample tomeasure its mechanical properties. Tests 1-7 and 14 were performedaccording to ASTM D3822-14, entitled STANDARD TEST METHOD FOR TENSILEPROPERTIES OF SINGLE TEXTILE FIBERS and published in 2014 (incorporatedherein by reference) (“ASTM D3822-14”), in dry conditions and in adirection of the length of the fabric. Tests 8-11 and 13 were performedusing a video microscope and micrometer. Test 12 was performed accordingto STM-00161, Revision 0 from Kimberly-Clark, which is entitled DENIERMEASUREMENT USING A VIDEO MICROSCOPE AND MICROMETER and published Jun.13, 2012 (incorporated herein by reference) (“STM-00161”). FIG. 6summarizes the results from these tests.

Example 2

The percent increase in tenacity (or strength) of spunbond fabricshaving blended fibers with various percentages of Polymer 2 and Polymer1 was tested according to ASTM D3822-14. FIG. 7 summarizes the resultsfrom these tests. As illustrated in FIG. 7, there is a generalcorrelation between the percent increase in tenacity and the percentageof the low MFR PP polymer (i.e., Polymer 2).

Example 3

Sample fabrics were formed by a spunbonding process and using a foursegment spinneret. The spunbond layers had different weights and fiberswith different percentages of Polymer 1 and Polymer 2, and were testedaccording to the standards described below. Each sample fabric was aspunbond layer of fibers. The average diameter of the fibers of eachsample fabric was 21 microns.

In this example, each sample was a single spunbond layer of the fibers.The samples had the compositions shown in Table 2 below.

TABLE 2 Compositions of Samples 9-14 Average diameter Weight HollownessSample % Polymer 1 % Polymer 2 (microns) (gsm) (%) 9 100 0 21 71 10.0 1030 70 21 71 17.0 11 20 80 21 71 24.0 12 100 0 21 34 10.0 13 30 70 21 3417.0 14 20 80 21 34 24.0

Trapezoidal Tear Strength: Samples 9-14 described above were testedaccording to Standard Test Method STM-00195, Revision 0 fromKimberly-Clark, which is entitled TEARING STRENGTH—TRAPEZOID TEAR andpublished Jul. 19, 2012 (incorporated herein by reference (“STM-00195”),a measured in both the cross-machine direction (CD) and the machinedirection (MD).

Strip Tensile Strength: Samples 9-14 described above were testedaccording to STM-00198, Revision 1 from Kimberly-Clark, which isentitled STRIP TENSILE OF NON-WOVEN MATERIAL and published Aug. 2, 2012(incorporated herein by reference) (“STM-00198”), and were measured inboth the machine direction and the cross-machine direction.

Puncture Resistance: Samples 9-14 described above were tested accordingto STM-00483, Revision 0 from Kimberly-Clark, which is entitled PUNCTURERESISTANCE and published Dec. 17, 2015 (incorporated herein byreference) (“STM-00483”), and were measured in both the machinedirection and the cross-machine direction.

Grab Tensile Strength: Samples 9-14 described above were testedaccording to STM-00146, Revision 1 from Kimberly-Clark, which isentitled GRAB TENSILE, PEAK STRETCH, AND PEAK ENERGY—NON-WOVENS andpublished Nov. 30, 2015 (incorporated herein by reference)(“STM-00146”), and were tested in both the machine direction and thecross-machine direction.

The results from these tests are summarized in FIG. 8. For each test,FIG. 8 also shows the percent change of Sample 10 over Sample 9, thepercent change of Sample 11 over Sample 9, the percent change of Sample13 over Sample 12, and the percent change of Sample 14 over Sample 12.As illustrated, the fabrics that included blended fibers that includedthe lower MFR polymers (i.e., Samples 10, 11, 13, and 14) demonstratedimproved physical properties compared to the fibers that only includedthe high MFR polymers (i.e., Samples 9 and 12). In addition, lowerweight fabrics with blended fibers (i.e., Samples 13 and 14)demonstrated improved physical properties in at least the machinedirection compared to Sample 12. Based on this, fabrics and othermaterials having fibers formed with a polymer blend that include lowerMFR polymers can improve the resistance to formation of holes, cuts,tears, etc. in such products. Fabrics with fibers from polymer blendsthat include lower MFR polymers may optionally allow for the productionof lighter weight fabrics or products while providing improvedmechanical properties, and may improve the mechanical properties ofproducts incorporating such fabrics.

Example 4

Sample fabrics were formed by a spunbonding process and using a foursegment spinneret. The spunbond layers had different weights, were madefrom hollow fibers having different percentages of Polymer 1 and Polymer2, and were tested for puncture resistance (according to STM-00483),grab tensile strength (according to STM-00146), trapezoidal tearstrength (according to STM-00195).

The compositions of sample fabrics represented by the diagonallystripped pattern bars and the solid pattern bars are shown in Table 3below. FIGS. 9 and 10 summarize the results from the tests of thesesample fabrics tests.

TABLE 3 Compositions of Sample Fabrics of FIGS. 9 and 10 Bar pattern inWeight Hollowness FIGS. 9 and 10 % Polymer 1 % Polymer 2 (gsm) (%)Diagonally 100 0 70 10 stripped Solid 20 80 58 16-25

As illustrated, fabrics with blended fibers formed from low MFR PPpolymers and high MFR PP polymers had improved mechanical propertiescompared to the fabrics with fibers that were just high MFR PP polymerseven though the fabrics with blended polymers had a reduced weight andthe fibers of such fabrics had increased hollowness.

Example 5

Sample fabrics were formed with different weights and from fibers havingdifferent average diameters and different percentages of Polymer 1 andPolymer 2 were tested for puncture resistance (according to STM-00483),grab tensile strength (according to STM-00146), and bursting strength(according to ISO 13932-2:1999, which is entitled TEXTILES—BURSTINGPROPERTIES OF FABRICS—PART 2: PNEUMATIC METHOD FOR DETERMINATION OFBURSTING STRENGTH AND BURSTING DISTENSION and published in 1999(incorporated herein by reference)).

Each fabric was produced as a SMS fabric having two spunbond layers anda meltblown layer laminated (calendered) between the spunbond layers.The weight of the meltblown layer was 17 gsm. In this example, thespunbond layer of each sample fabric was formed with a two segmentspinneret. The meltblown layer included 100% meltblown gradepolypropylene having a MFR of from about 155 MFR to about 800 MFR.

The composition of the samples in this example are shown below in Table4.

TABLE 4 Compositions of Samples 15-19 Total Hollow Average weight %Polymer 1 % Polymer 2 or solid diameter of (spunbond in fibers in fibersfibers fibers forming Total weight + forming forming forming spunbondspunbond meltblown spunbond spunbond spunbond layers weight weight)Sample layer layers layers? (microns) (gsm) (gsm) 15 100 0 Solid 20 35.552.5 16 100 0 Solid 15 35.5 52.5 17 20 80 Hollow 18 35.5 52.5 18 100 0Hollow 18 35.5 52.5 19 20 80 Solid 19 35.5 52.5

FIG. 11 summarizes the percent change when the testing results for thesamples were compared to each other. The bars with the downward diagonalpattern represent the percent change of Sample 16 compared to Sample 15.The bars with the solid pattern represent the percent change of Sample17 compared to Sample 15. The bars with the upward diagonal patternrepresent the percent change of Sample 18 compared to Sample 15. Thebars with the horizontal line pattern represent the percent change ofSample 19 compared to Sample 15.

Referring to the downward diagonal pattern bars of FIG. 11, the fabricshaving solid fibers with 100% high MFR polymers and the reduced averagediameter (15 microns) generally had increased mechanical propertiescompared to the fabrics with solid fibers with 100% high MFR polymersand the increased average diameter (20 microns). Without being bound byany theory, it is believed that in the fabrics with fibers having areduced average diameter, the fibers have increased contact with otherfibers, and the increased contact provides improved strength.

Referring to the solid pattern bars of FIG. 11, the fabrics with thehollow fibers with the blend and reduced average diameter (18 microns)generally had increased mechanical properties compared to the fabricswith the solid fibers with 100% high MFR polymers and the increasedaverage diameter (20 microns). Without being bound by any theory, it isbelieved that the fabrics with the fibers formed from the polymer blendprovide improved strength, and it is also believed that the fibershaving the reduced average diameter have increased contact with otherfibers in the fabric, which also provides improved strength. Withoutbeing bound by any theory, it is also believed that the hollowness ofthe fibers of the fabric allows for the sample fabric with the hollowblended fibers to provide the improved strength when provided in afabric at the same weight as the solid fibers. Conversely, to achievethe same mechanical properties as a fabric with the solid fibers, asample fabric with blended hollow fibers at a reduced weight could beused.

Referring to the upward diagonal pattern bars of FIG. 11, the fabricwith the hollow fibers with 100% high MFR polymers and the reducedaverage diameter (18 microns) generally had increased mechanicalproperties compared to the fabric with the solid fibers with 100% highMFR polymers and the increased average diameter (20 microns). Withoutbeing bound by any theory, it is believed the fibers with reducedaverage diameter have increased contact with other fibers in the fabric,and the increased contact provides improved strength to the fabric.Without being bound by any theory, it is also believed that thehollowness of the fibers allows for the sample fabric with the hollowfibers to provide the improved strength when provided at the same weightas fabrics with the solid fibers. Conversely, to achieve the samemechanical properties as fabrics with the solid fibers, a sample fabricwith hollow fibers at a reduced weight could be used.

Referring to the bars with the horizontal line pattern, the fabric withsolid fibers with blend and the reduced average diameter (18 microns)generally had increased mechanical properties compared to the fabricwith solid fibers with 100% high MFR polymers and the increased averagediameter (20 microns). Without being bound by any theory, it is believedthat the fabric with the fibers formed from the polymer blend providesimproved strength, and it is also believed that the fibers with thereduced average diameter have increased contact with other fibers, whichalso provides improved strength to the fabric.

From FIG. 11, it can be seen that the blend of polymers provides thebiggest improvement to mechanical properties of the product. The reducedaverage diameter and the hollowness of the fibers also improves themechanical properties of the product. Based on FIG. 9, the polymerblend, fiber average diameter, and/or hollowness of the fibers can becontrolled to provide fibers with desired improved mechanicalproperties.

Example 6

Sample spunbond fabrics were formed with fibers having different averagediameters and different percentages of Polymer 1 and Polymer 2, and thefabrics were tested for puncture resistance (according to STM-00483) andgrab tensile strength (according to STM-00146). Each fabric was producedas a SMS fabric having two spunbond layers and a meltblown layerlaminated (calendered) between the spunbond layers. The weight of eachfabric was the same, but the polymer blend, hollowness of the fibers,and average diameter of the fibers was varied in each sample. In thisexample, the fibers were formed with a two segment spinneret.

The compositions of sample fabrics represented by the diagonallystripped pattern bars and the solid pattern bars are shown in Table 5below. FIG. 12 summarizes the results from the tests of these samplefabrics.

TABLE 5 Compositions of Sample Fabrics of FIG. 12 Average Hollow or Barpattern in diameter solid FIG. 12 % Polymer 1 % Polymer 2 (microns)fibers? Downward 20 80 18 Hollow diagonal Solid 20 80 18 Solid Upward100 0 15 Solid diagonal Horizontal line 100 0 20 Solid

From FIG. 12, it can be seen that the blended polymers, the reducedaverage diameter fibers, and hollow fibers in various combinationsimproved mechanical properties compared to the unblended, solid fiberswith the increased average diameter (i.e., represented by the bars withthe horizontal line pattern).

Example 7

Sample fabrics were formed with different weights and from fibers havingdifferent average diameters and different percentages of Polymer 1 andPolymer 2. Each fabric was produced as a SMS fabric having two spunbondlayers and a meltblown layer laminated (calendered) between the spunbondlayers. The weight of the meltblown layer was 17 gsm. In this example,the spunbond layer of each sample fabric was formed with a two segmentspinneret. The fabrics were tested for puncture resistance (according toSTM-00483), grab tensile strength (according to STM-00146), andtrapezoidal tear strength (according to STM-00195).

The composition of the samples in this example are shown below in Table6. FIGS. 13 and 14 summarize the results from these tests for thedifferent fabrics.

TABLE 6 Compositions of Sample Fabrics of FIGS. 13 and 14 Total HollowAverage weight % Polymer % Polymer 2 or solid diameter of (spunbond Bar1 in fibers in fibers fibers fibers forming Total weight + pattern informing forming forming spunbond spunbond meltblown FIGS. 13 spunbondspunbond spunbond layers weight weight) and 14 layer layers layers?(microns) (gsm) (gsm) Downward 20 80 Hollow 18 25.5 42.5 diagonal Solid20 80 Solid 17 25.5 42.5 Upward 100 0 Solid 20 35.5 52.5 diagonal

From FIGS. 13 and 14, it can be seen that the blended of polymers, fiberaverage diameter, hollowness of the fibers, and weight of the fabric canbe controlled to improve mechanical properties as desired.

Exemplary Embodiments

A collection of exemplary embodiments (EEs), including at least someexplicitly enumerated, providing additional description of a variety ofembodiment types in accordance with the concepts described herein areprovided below. These examples are not meant to be mutually exclusive,exhaustive, or restrictive; and the invention is not limited to theseexample embodiments but rather encompasses all possible modificationsand variations within the scope of the issued claims and theirequivalents.

EE 1. A fiber comprising a fiber body, the fiber body comprising a blendof a first polymer and a second polymer, wherein a melt flow rate (MFR)of the first polymer is greater than a MFR of the second polymer,wherein the blend comprises at least 10% by weight of the secondpolymer, and wherein the hollow fiber is formed as a spunbond layer on aREICOFIL® III line or on a REICOFIL® IV line.

EE 2. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the spunbond layercomprising the fiber has an improved mechanical property in at least oneof a machine direction or a cross-machine direction compared to a fibercomprising only the first polymer.

EE 3. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the improved mechanicalproperty comprises at least one of a trap tear strength, a strip tensilestrength, a puncture resistance, and a grab tensile strength, andwherein the at least one direction is the machine direction.

EE 4. A spunbond comprising the fiber of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, wherein aweight of the spunbond layer is less than about 105 gsm.

EE 5. A spunbond non-woven fabric comprising the fiber of any precedingor subsequent exemplary embodiments or combination of exemplaryembodiments.

EE 6. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the fiber body is a hollowand defines a hollow cavity within the fiber body, and wherein thehollow cavity comprises up to about 25% of the fiber body.

EE 7. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the spunbond layercomprising the fiber is formed with at least one of a two segmentspinneret, a three segment spinneret, or a four segment spinneret.

EE 8. A fiber comprising a fiber body extending in a longitudinaldirection, the fiber body comprising a blend of a first polymer and asecond polymer, wherein a melt flow rate (MFR) of the first polymer isgreater than a MFR of the second polymer, wherein the blend comprises atleast 10% by weight of the second polymer, and wherein the fiber isformed as a spunbond layer on a REICOFIL® III line or on a REICOFIL® IVline.

EE 9. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the spunbond layercomprising the fiber has an improved mechanical property in at least oneof a machine direction or a cross-machine direction compared to aspunbond fabric comprising a fiber comprising only the first polymer.

EE 10. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the improved mechanicalproperty comprises at least one of a trap tear strength, a strip tensilestrength, a puncture resistance, and a grab tensile strength, andwherein the at least one direction is the machine direction.

EE 11. A spunbond comprising the fiber of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, wherein aweight of the spunbond layer is less than about 105 gsm.

EE 12. A spunbond non-woven fabric comprising the fiber of any precedingor subsequent exemplary embodiments or combination of exemplaryembodiments.

EE 13. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the fiber body is a hollowand defines a hollow cavity within the fiber body.

EE 14. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the spunbond layercomprising the fiber is formed with at least one of a two segmentspinneret, a three segment spinneret, or a four segment spinneret.

EE 15. A fiber comprising a fiber body, the fiber body comprising ablend of a first polymer and a second polymer, wherein a melt flow rate(MFR) of the first polymer is greater than a MFR of the second polymer,wherein the blend comprises at least 10% by weight of the secondpolymer, and wherein a spunbond layer of a non-woven fabric comprisesthe fiber, and wherein the spunbond layer has a weight of less thanabout 105 gsm.

EE 16. A spunbond comprising the fiber of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, wherein aweight of a spunbond comprising the fiber is less than about 105 gsm.

EE 17. The fiber of any preceding or subsequent exemplary embodiments orcombination of exemplary embodiments, wherein the fiber body is a hollowand defines a hollow cavity within the fiber body.

EE 18. A spunbond non-woven fabric comprising a plurality of fibers,wherein each fiber comprises: a blend of a first polymer and a secondpolymer, wherein a melt flow rate (MFR) of the first polymer is greaterthan a MFR of the second polymer, wherein the blend comprises 20%-30% byweight of the first polymer; and a fiber average diameter of from about15 microns to about 20 microns, and wherein a calendar bond area of thefabric comprises a bond area of from about 15% to about 35%.

EE 19. A hollow fiber comprising a fiber body extending in alongitudinal direction and defining a hollow cavity within the fiberbody, wherein the fiber body comprises a blend of a first polymer and asecond polymer, wherein a melt flow rate (MFR) of the first polymer isgreater than a MFR of the second polymer, and wherein the blendcomprises at least 10% by weight of the second polymer.

EE 20. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the blendcomprises 10% to 70% by weight of the second polymer.

EE 21. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the MFR ofthe first polymer is greater than 18 g/10 min.

EE 22. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the MFR ofthe second polymer is from about 9 g/10 min to about 18 g/10 min.

EE 23. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the firstpolymer and the second polymer each comprise a polyolefin.

EE 24. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the hollowcavity comprises from about 5% to about 40% of the fiber body.

EE 25. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the hollowcavity comprises from about 10% to about 30% by volume of the fiberbody.

EE 26. A spunbond non-woven fabric comprising the hollow fiber of anypreceding or subsequent exemplary embodiments or combination ofexemplary embodiments.

EE 27. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, further comprisinga sheath layer, the sheath layer comprising a third polymer, wherein aMFR of the third polymer is greater than the MFR of the second polymer.

EE 28. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the MFR ofthe third polymer is the same as the MFR of the first polymer.

EE 29. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the thirdpolymer comprises a polyolefin.

EE 30. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the sheathlayer further comprises an additive, and wherein the additive comprisesat least one of a fluorochemical, an antimicrobial, a surfactant, and acolor pigment.

EE 31. A non-woven fabric comprising the hollow fiber of any precedingor subsequent exemplary embodiments or combination of exemplaryembodiments.

EE 32. A hygiene product comprising the spunbond non-woven fabric of anypreceding or subsequent exemplary embodiments or combination ofexemplary embodiments, wherein the hygiene product comprises at leastone of a surgical gown, a drape, gloves, facemasks, and protectiveapparel, surgical gowns, sterilization wraps, respirators, absorbentpads, wound care products, chemical protection apparel, filtrationmedia, hospital towels, hospital apparel, drapes, gloves, facemasks,sanitary napkins, and diapers.

EE 33. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the blendfurther comprises a third polymer.

EE 34. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the MFR ofthe third polymer is less than the MFR of the first polymer.

EE 35. The hollow fiber of any preceding or subsequent exemplaryembodiments or combination of exemplary embodiments, wherein the MFR ofthe third polymer is less than the MFR of the second polymer.

EE 36. A method of manufacturing a spunbond layer of a non-woven fabric,the method comprising producing a plurality of fibers by: mixing a firstpolymer with a second polymer into a blend, wherein a melt flow rate(MFR) of the first polymer is greater than a MFR of the second polymer,and wherein the blend comprises at least 10% by weight of the secondpolymer; drawing the blend through a spinneret to form the plurality offibers; quenching the fibers; and depositing the fibers as a web.

EE 37. The method of any preceding or subsequent exemplary embodimentsor combination of exemplary embodiments, wherein the blend comprises 10%to 70% by weight of the second polymer.

EE 38. The method of any preceding or subsequent exemplary embodimentsor combination of exemplary embodiments, wherein the MFR of the firstpolymer is greater than 18 g/10 min, and wherein the MFR of the secondpolymer is from about 9 g/10 min to about 18 g/10 min.

EE 39. The method of any preceding or subsequent exemplary embodimentsor combination of exemplary embodiments, wherein the first polymer andthe second polymer each comprise a polyolefin.

EE 40. The method of any preceding or subsequent exemplary embodimentsor combination of exemplary embodiments, further comprising forming anon-woven fabric with the spunbond layer.

EE 41. The method of any preceding or subsequent exemplary embodimentsor combination of exemplary embodiments, wherein forming the non-wovenfabric comprises forming a surgical product, wherein the surgicalproduct comprises at least one of a surgical gown, a drape, gloves,facemasks, and protective apparel.

EE 42. A spunbond non-woven fabric comprising a plurality of fibers,wherein the fibers are formed from a polymer blend comprising at leastone first polymer and at least one second polymer, wherein a melt flowrate (MFR) of the at least one first polymer is greater than a MFR ofthe at least one second polymer, wherein the MFR of the at least onesecond polymer is less than 18 g/10 min, and wherein the blend comprisesa percentage by weight of the second polymer that is greater than apercentage by weight of the first polymer.

EE 43. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, wherein aweight of the fabric is less than about 105 gsm, and wherein the fabrichas a mechanical property in a machine direction that is greater thanthe mechanical property in the machine direction of a spunbond fabriccomprising fibers formed from only the first polymer and under the sameconditions, and wherein the mechanical property comprises at least oneof a trap tear strength, a strip tensile strength, a punctureresistance, or a grab tensile strength.

EE 44. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe weight of the fabric is from about 8 gsm to about 15 gsm.

EE 45. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe MFR of the at least one first polymer is from greater than 18 g/10min to about 40 g/10 min.

EE 46. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe fibers each comprise a fiber body that surrounds and defines acavity, wherein the fiber body and the cavity together define a totalvolume, and wherein the fibers comprise a hollowness of up to about 25%by volume of the total volume.

EE 47. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe polymer blend comprises 50% to 90% by weight of the at least onesecond polymer.

EE 48. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinan average diameter of each fiber is from about 13 microns to about 22microns.

EE 49. A non-woven fabric comprising the spunbond non-woven fabric ofany preceding or subsequent exemplary embodiments or combination ofexemplary embodiments as a first spunbond layer, wherein the non-wovenfabric further comprises a second spunbond layer and a meltblown layerlaminated between the first spunbond layer and the second spunbondlayer, and wherein the second spunbond layer comprises a plurality offibers, each formed from a polymer blend comprising the at least onefirst polymer and the at least one second polymer.

EE 50. A spunbond non-woven fabric comprising a plurality of fibers,wherein the fibers are formed from a polymer blend comprising at leastone first polymer and at least one second polymer, wherein a melt flowrate (MFR) of the at least one first polymer is from about 19 g/10 minto about 40 g/10 min, wherein a MFR of the at least one second polymeris about 9 g/10 min to about 18 g/10 min, wherein the blend comprises atleast 10% by weight of the at least one second polymer, and wherein anaverage diameter of each fiber is from about 13 microns to about 22microns.

EE 51. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, wherein aweight of the fabric is less than about 105 gsm, and wherein the fabrichas a mechanical property in a machine direction that is greater themechanical property in the machine direction of a spunbond fabriccomprising fibers formed from only the first polymer and under the sameconditions, and wherein the mechanical property comprises at least oneof a trap tear strength, a strip tensile strength, a punctureresistance, or a grab tensile strength.

EE 52. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinweight of the spunbond non-woven fabric is from about 42 gsm to about 52gsm.

EE 53. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe polymer blend comprises 20% to 90% by weight of the at least onesecond polymer.

EE 54. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe fibers each comprise a fiber body that surrounds and defines acavity, wherein the fiber body and the cavity together define a totalvolume, and wherein the fibers comprise a hollowness up to about 25% byvolume of the total volume.

EE 55. A non-woven fabric comprising the spunbond non-woven fabric ofclaim 9 as a first spunbond layer, wherein the non-woven fabric furthercomprises a second spunbond layer and a meltblown layer laminatedbetween the first spunbond layer and the second spunbond layer, andwherein the second spunbond layer comprises a plurality of fibers formedfrom a polymer blend comprising the at least one first polymer and theat least one second polymer.

EE 56. A spunbond non-woven fabric comprising a plurality of hollowfibers, wherein the hollow fibers are formed from a polymer blendcomprising at least one first polymer and at least one second polymer,wherein a melt flow rate (MFR) of the at least one first polymer isgreater than a MFR of the at least one second polymer, wherein the MFRof the at least one second polymer is about 9 g/10 min to less than 18g/10 min, wherein the blend comprises at least 10% by weight of thesecond polymer, wherein the hollow fibers each comprise a fiber bodythat defines a cavity within the fiber body, wherein the cavity and thefiber body together define a total volume, and wherein the fiberscomprise a hollowness of at least 5% by volume of the total volume.

EE 57. The spunbond non-woven fabric of claim 14, wherein the fiberscomprise a hollowness up to about 40% by volume of the total volume

EE 58. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe polymer blend comprises 20% to 90% by weight of the at least onesecond polymer.

EE 59. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe MFR of the at least one first polymer is from about 19 g/10 min toabout 40 g/10 min.

EE 60. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinan average diameter of each fiber is from about 13 microns to about 22microns.

EE 61. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, whereinthe at least one first polymer and the at least one second polymer eachcomprise a polyolefin.

EE 62. The spunbond non-woven fabric of any preceding or subsequentexemplary embodiments or combination of exemplary embodiments, wherein aweight of the spunbond non-woven fabric is less than about 105 gsm, andwherein the spunbond non-woven fabric has an improved mechanicalproperty in a machine direction compared to a spunbond fabric comprisinga spunbond non-woven fiber comprising fibers comprising only the firstpolymer, and wherein the improved mechanical property comprises at leastone of a trap tear strength, a strip tensile strength, a punctureresistance, and a grab tensile strength.

The above-described aspects are merely possible examples ofimplementations, merely set forth for a clear understanding of theprinciples of the present disclosure. Many variations and modificationscan be made to the above-described embodiment(s) without departingsubstantially from the spirit and principles of the present disclosure.All such modifications and variations are intended to be included hereinwithin the scope of the present disclosure, and all possible claims toindividual aspects or combinations of elements or steps are intended tobe supported by the present disclosure. Moreover, although specificterms are employed herein, as well as in the claims that follow, theyare used only in a generic and descriptive sense, and not for thepurposes of limiting the described invention, nor the claims thatfollow.

That which is claimed:
 1. A spunbond non-woven fabric comprising aplurality of fibers, wherein the fibers are formed from a polymer blendcomprising at least one first polymer and at least one second polymer,wherein a melt flow rate (MFR) of the at least one first polymer isgreater than a MFR of the at least one second polymer, wherein the MFRof the at least one second polymer less than 18 g/10 min, and whereinthe polymer blend comprises a percentage by weight of the second polymerthat is greater than a percentage by weight of the first polymer.
 2. Thespunbond non-woven fabric of claim 1, wherein a weight of the fabric isfrom about 42.5 gsm to less than about 105 gsm, and wherein the fabrichas a mechanical property that is greater than the mechanical propertyof a spunbond fabric comprising fibers formed from only the firstpolymer and under the same conditions, and wherein the mechanicalproperty comprises at least one of a trap tear strength, a strip tensilestrength, a puncture resistance, or a grab tensile strength.
 3. Thespunbond non-woven fabric of claim 2, wherein the mechanical property isat least 20% greater than the mechanical property of the spunbond fabriccomprising fibers formed from only the first polymer under the sameconditions.
 4. The spunbond non-woven fabric of claim 1, wherein aweight of the fabric is less than about 105 gsm, and wherein the fabrichas a mechanical property in a machine direction that is greater thanthe mechanical property in the machine direction of a spunbond fabriccomprising fibers formed from only the first polymer and under the sameconditions, and wherein the mechanical property comprises at least oneof a trap tear strength, a strip tensile strength, a punctureresistance, or a grab tensile strength.
 5. The spunbond non-woven fabricof claim 4, wherein the weight of the fabric is from about 8 gsm toabout 15 gsm.
 6. The spunbond non-woven fabric of claim 1, wherein theMFR of the at least one first polymer is from greater than 18 g/10 minto about 40 g/10 min.
 7. The spunbond non-woven fabric of claim 1,wherein the fibers each comprise a fiber body that surrounds and definesa cavity, wherein the fiber body and the cavity together define a totalvolume, and wherein the fibers comprise a hollowness of up to about 25%by volume of the total volume.
 8. The spunbond non-woven fabric of claim1, wherein the polymer blend comprises 50% to 90% by weight of the atleast one second polymer.
 9. The spunbond non-woven fabric of claim 1,wherein an average diameter of each fiber is from about 13 microns toabout 22 microns.
 10. A non-woven fabric comprising the spunbondnon-woven fabric of claim 1 as a first spunbond layer, wherein thenon-woven fabric further comprises a second spunbond layer and ameltblown layer laminated between the first spunbond layer and thesecond spunbond layer, and wherein the second spunbond layer comprises aplurality of fibers, each formed from a polymer blend comprising the atleast one first polymer and the at least one second polymer.
 11. Aspunbond non-woven fabric comprising a plurality of fibers, wherein thefibers are formed from a polymer blend comprising at least one firstpolymer and at least one second polymer, wherein a melt flow rate (MFR)of the at least one first polymer is from about 19 g/10 min to about 40g/10 min, wherein a MFR of the at least one second polymer is about 9g/10 min to about 18 g/10 min, wherein the blend comprises 10% to 99% byweight of the at least one second polymer, and wherein an averagediameter of each fiber is from about 13 microns to about 22 microns. 12.The spunbond non-woven fabric of claim 11, wherein the fibers eachcomprise a fiber body that surrounds and defines a cavity, wherein thefiber body and the cavity together define a total volume, and whereinthe fibers comprise a hollowness of at least 5% by volume of the totalvolume.
 13. The spunbond non-woven fabric of claim 12, wherein thefibers comprise a hollowness up to about 40% by volume of the totalvolume.
 14. The spunbond non-woven fabric of claim 13, wherein thefibers comprise a hollowness up to about 25% by volume of the totalvolume.
 15. The spunbond non-woven fabric of claim 11, wherein thepolymer blend comprises 20% to 90% by weight of the at least one secondpolymer.
 16. A non-woven fabric comprising the spunbond non-woven fabricof claim 11 as a first spunbond layer, wherein the non-woven fabricfurther comprises a second spunbond layer and a meltblown layerlaminated between the first spunbond layer and the second spunbondlayer, and wherein the second spunbond layer comprises a plurality offibers formed from a polymer blend comprising the at least one firstpolymer and the at least one second polymer.
 17. The spunbond non-wovenfabric of claim 11, wherein the at least one first polymer and the atleast one second polymer each comprise a polyolefin.
 18. The spunbondnon-woven fabric of claim 11, wherein a total weight of the fabric isfrom about 42.5 gsm to less than about 105 gsm, and wherein the fabrichas a mechanical property—that is at least 5% greater than themechanical property of a spunbond fabric comprising fibers formed fromonly the first polymer and under the same conditions, and wherein themechanical property comprises at least one of a trap tear strength, astrip tensile strength, a puncture resistance, or a grab tensilestrength.
 19. The spunbond non-woven fabric of claim 18, wherein themechanical property is at least 20% greater than the mechanical propertyof the spunbond fabric comprising fibers formed from only the firstpolymer and under the same conditions.
 20. The spunbond non-woven fabricof claim 18, wherein the fibers each comprise a fiber body thatsurrounds and defines a cavity, wherein the fiber body and the cavitytogether define a total volume, and wherein the fibers comprise ahollowness of at least 5% by volume of the total volume.